Armature of rotary electric machine, rotary electric machine, and method for manufacturing lead wire of armature of rotary electric machine

Abstract

The present invention comprises: an armature core (31) that has a yoke portion (31a) formed in an annular shape and a plurality of tooth portions (31b) protruding inward (X2) in the radial direction (X) from the inner circumference side of the yoke portion (31a) and formed at intervals in the circumferential direction (Z); an insulating member (33) installed on each of the tooth portions (31b); a coil (32) wound around the tooth portions (31b) via an insulating member (33); and a lead wire (14) electrically connected to at least one of the winding start terminal portion or the winding end terminal portion of the coil (32). The lead wire (14) has a plurality of bent portions (15c1 to 15c4) when viewed from the axial direction (Y).

Description

Rotating electric machine armature, rotating electric machine, and method for manufacturing armature lead wire for rotating electric machine

[0001] The present disclosure relates to an armature for a rotating electric machine, a rotating electric machine, and a method for manufacturing a lead wire for an armature for a rotating electric machine.

[0002] A conventional armature for a rotating electric machine includes a stator core having a plurality of magnetic pole teeth along its inner periphery, and windings wound around each magnetic pole tooth of the stator core via insulating members. The end face of the stator core is provided with a restraining portion that restrains the winding terminals. The restraining portion has a restraining groove that restrains the winding start terminal or the winding end terminal. The restraining groove also restrains a crossover wire that connects the winding start terminals to each other, connects a power supply lead wire, and connects the winding end terminals to each other and forms a neutral point. The restrained winding terminals and the crossover wire are connected by a metal piece fitted into the restraining portion. The crossover wire is shaped like a circular arc and passes over each magnetic pole tooth to connect the desired windings, facilitating the connection between the armature windings (see, for example, Patent Document 1).

[0003] Patent No. 6977820

[0004] In armatures of conventional rotating electric machines, the crossover wires are formed into an arc, so if a thick solid wire is used for the crossover wire, for example, the crossover wire has high rigidity and tends to return to its original shape due to springback, making it difficult to maintain its shape. As a result, when inserting the crossover wire into the restraining groove and wiring it along the magnetic pole teeth, it is necessary to wire it again along the desired shape, which presents a problem of poor workability.

[0005] Furthermore, in order to form the crossover wire into the desired shape, the conductor wire must be pressed into a mold that matches the shape, but a mold is required for each crossover wire shape, which creates the problem of increased mold costs.

[0006] Furthermore, since the crossover wire is not restrained midway when it is placed, the crossover wire becomes unstable. For example, if the crossover wire shifts when wiring another crossover wire or when inserting a metal piece into the restraining groove, work must be done to reposition the crossover wire to the desired position, which creates the problem that the time required for wiring the crossover wire cannot be shortened.

[0007] Furthermore, even after wiring, if external forces are applied to the crossover wires due to material handling or vibrations in later processes, the crossover wires may become misaligned or fall off, which poses the problem of requiring time and effort to correct.

[0008] The present disclosure discloses technology for solving the above-mentioned problems, and aims to provide an armature for a rotating electric machine, a rotating electric machine, and a method for manufacturing lead wires for an armature of a rotating electric machine that allows for easy wiring of lead wires, shortens work time, and reduces investment costs.

[0009] The presently disclosed armature for a rotating electric machine includes an armature core having an annular yoke portion and a plurality of teeth protruding radially inward from the inner periphery of the yoke portion and spaced apart in the circumferential direction, insulating members installed on each of the teeth, coils wound around the teeth via the insulating members, and lead wires electrically connected to at least one of a winding start end and a winding end end of the coil, wherein the lead wires have a plurality of bent portions when viewed axially. The presently disclosed rotating electric machine includes the above-described armature for a rotating electric machine. The presently disclosed method for manufacturing a lead wire for an armature for a rotating electric machine includes repeating a feeding process of feeding out a reel-shaped wire by a predetermined length and a bending process of bending the wire at a predetermined angle, and then cutting the wire at a predetermined position to form the lead wire having a plurality of bent portions.

[0010] According to the disclosed rotating electric machine armature, rotating electric machine, and method for manufacturing lead wires for a rotating electric machine armature, the wiring work for lead wires can be easily performed, the work time can be shortened, and investment costs can be reduced.

[0011] 6 is a cross-sectional view showing the configuration of a rotating electric machine according to embodiment 1. FIG. 3A is a perspective view showing the configuration of an insulator for the armature of the rotating electric machine shown in FIG. 1 , and FIG. 3B is a perspective view showing the configuration of an insulator for the armature of the rotating electric machine shown in FIG. 1 . FIG. 3B is a perspective view showing the configuration of a winding assembly for the armature of the rotating electric machine shown in FIG. 1 . FIG. 4 is a plan view showing a state in which lead wires are wired to the armature of the rotating electric machine shown in FIG. 5 . FIG. 5 is a plan view explaining a process for wiring lead wires to the armature of the rotating electric machine shown in FIG. 5 . FIG. 6 is a perspective view explaining a process for wiring another lead wire after the process shown in FIG. 6 . FIG. 7 is a diagram explaining a manufacturing process for a lead wire for the armature of the rotating electric machine according to embodiment 1. FIG. 8 is a diagram explaining a manufacturing process for a lead wire for the armature of the rotating electric machine according to embodiment 1. FIG. 9 is a diagram explaining a manufacturing process for a lead wire for the armature of the rotating electric machine according to embodiment 1. FIG. 10 is a diagram explaining a manufacturing process for a lead wire for the armature of the rotating electric machine according to embodiment 1. FIG. 11 is a diagram explaining a manufacturing process for a lead wire for the armature of the rotating electric machine according to embodiment 1. 25A is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 1. FIG. 25B is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 1. FIG. 25A is a diagram illustrating a manufacturing process for a lead wire of an armature of an armature of a rotating electric machine according to embodiment 1. FIG. 25B is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 1. FIG. 25A is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 1. FIG. 25B is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 2. FIG. 25B is a diagram illustrating a configuration of an armature of a rotating electric machine according to embodiment 2. FIG. 25A is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 2. FIG. 25B is a diagram illustrating a manufacturing process for a lead wire of an armature of a rotating electric machine according to embodiment 1.FIG. 25C is a cross-sectional view showing another wire material that forms the lead wires and crossover wires of the rotary electric machine according to the third embodiment.

[0012] In the following description, the various directions in the rotating electric machine 100 are respectively referred to as the circumferential direction Z, the axial direction Y, the radial direction X, the outer side X1 of the radial direction X, and the inner side X2 of the radial direction X. Therefore, these directions are the same in other parts as well, and the various directions will be described based on these directions.

[0013] Embodiment 1. Fig. 1 is a cross-sectional view showing the configuration of a rotating electric machine according to embodiment 1. Fig. 2 is a perspective view showing the configuration of a laminated core of the armature of the rotating electric machine shown in Fig. 1. Fig. 3 is a perspective view showing the configuration of an insulator of the armature of the rotating electric machine shown in Fig. 1, Fig. 3A is a perspective view showing the configuration of an insulator on the connection side in the axial direction Y, and Fig. 3B is a perspective view showing the configuration of an insulator on the anti-connection side in the axial direction Y. Fig. 4 is a perspective view showing the configuration of a winding assembly of the armature of the rotating electric machine shown in Fig. 1.

[0014] Fig. 5 is a plan view showing lead wires wired to the armature of the rotating electric machine shown in Fig. 1. Fig. 6 is a plan view illustrating the process of wiring lead wires to the armature of the rotating electric machine shown in Fig. 5. Fig. 7 is a plan view illustrating the process of wiring lead wires to the armature of the rotating electric machine shown in Fig. 5. Fig. 8 is a perspective view illustrating the process of wiring another lead wire after the process shown in Fig. 6. Figs. 9 to 17 and 23 are views illustrating the manufacturing process of the lead wires of the armature of the rotating electric machine according to embodiment 1. Fig. 24 is a perspective view showing a configuration in which lead wires are fixed by molding to the armature of the rotating electric machine shown in Fig. 5.

[0015] As shown in FIG. 1 , the rotating electric machine 30 includes an armature 36 and a field element 37. The armature 36 includes a winding assembly 34 arranged in an annular shape, in which a coil 32 is wound around a laminated core 31 serving as an armature core, with an insulator 33 serving as an insulating member interposed therebetween. The armature 36 is installed in a frame 35 by press-fitting or shrink-fitting. The field element 37 is arranged on the inner periphery of the armature 36 and includes a permanent magnet. The rotating electric machine 30 further includes a bracket 38a on the connection side and a bracket 38b on the non-connection side that hold the armature 36 and field element 37, and a power connector 39. The field element 37 is rotatably held by the brackets 38a and 38b via bearings (not shown).

[0016] As shown in Fig. 2, the laminated core 31 is formed of a plurality of electromagnetic steel sheets 310 stacked in the axial direction Y. A yoke portion 31a extending in the circumferential direction Z is formed on the outer peripheral side of the laminated core 31 on the outer side X1 in the radial direction X. Teeth portions 31b protruding from the center of the yoke portion 31a in the circumferential direction Z to the inner side X2 in the radial direction X are formed on the inner peripheral side of the yoke portion 31a on the inner side X2 in the radial direction X. Protrusions 31c extending on both sides in the circumferential direction Z are formed at the ends of the laminated core 31 on the inner side X2 in the radial direction X.

[0017] As shown in FIG. 3 , the insulator 33 includes two insulators 33a and 33b. When referring to either or both of the insulators, the term "insulator 33" is used. As shown in FIG. 3A , the insulator 33a attached to the wire connection side of the laminated core 31 in the axial direction Y includes an outer flange 33a1, an inner flange 33a2, and a body portion 33a3. The outer flange 33a1 includes a first restraining groove 33c and a second restraining groove 33d. As shown in FIG. 3B , the insulator 33b attached to the non-wire connection side of the laminated core 31 in the axial direction Y includes an outer flange 33b1, an inner flange 33b2, and a body portion 33b3.

[0018] 4 , in the winding assembly 34, the outer flanges 33a1 and 33b1 of the insulators 33a and 33b cover the yoke portion 31a from both sides in the axial direction Y, the inner flanges 33a2 and 33b2 cover the protrusions 31c from both sides in the axial direction Y, and the trunk portions 33a3 and 33b3 cover the teeth 31b from both sides in the axial direction Y. In this manner, the insulators 33a and 33b are attached to the laminated core 31, and the coil 32 is wound thereon to form the winding assembly 34. The coil 32 is wound around the teeth 31b via the insulators 33a and 33b. Although not shown, an insulating member such as an insulating film is disposed between both side surfaces of the laminated core 31 in the circumferential direction Z and the wound coil 32.

[0019] In this example, the winding assembly 34 is formed by continuously winding the winding assembly 34 around the laminated core 31, to which another insulator 33a, 33b is attached, starting from the insulator 33b on the anti-connection side, and the coil 32 is formed by a set of continuous windings of two winding assemblies 34. Note that, although an example has been shown in which a set of two continuously wound coils 32 is wound around the winding assemblies 34, the present invention is not limited to this, and the coils may be wound with one winding assembly each, or, for example, the coil may be formed by continuously winding three winding assemblies.

[0020] The coil terminal portion 32a of the coil 32 constituting the winding assembly 34 is inserted into the first restraining groove 33c of the insulator 33a on the wire connection side in the axial direction Y, and later the terminal portion of the lead wire 14 is inserted into the second restraining groove 33d in a manner that protrudes from the radially inner side to the outer peripheral side of the outer flange portion 33a1. The plurality of winding assemblies 34 thus formed are then arranged in an annular shape and fitted into the frame 35 by press fitting or shrink fitting, thereby forming the armature 36.

[0021] As shown in Figure 5, the coil 32 wound around the insulator 33 is electrically connected to the lead wire 14. The lead wire 14 is electrically connected to at least one of the winding start terminal portion or the winding end terminal portion of the coil 32, and in this case, it is a power supply line 14a that inputs the U, V, and W phases of three-phase AC from outside to the coil 32, and a crossover wire 15 that serves as a neutral line and connects between the coils 32. Furthermore, in order to connect the U, V, and W phase power supply lines 14a to a power connector 39, an input portion 14b that is the end of the power supply line 14a is provided.

[0022] When viewed from the axial direction Y, the lead wire 14 is disposed on the wound coil 32 of the insulator 33. Therefore, bent portions 15c1, 15c2, 15c3, and 15c4 (see FIGS. 7 and 8) of the lead wire 14, which will be described later, are disposed in the region where the coil 32 is wound between the outer flange 33a1 and the inner flange 33a2 of the insulator 33. In the following description, any or all of the bent portions of the lead wire 14 may be referred to as bent portion 15c.

[0023] The lead wire 14 is made of a highly conductive wire material such as copper or aluminum, covered with a highly insulating coating such as vinyl. The wire material may be a stranded wire, but a solid wire with high rigidity is preferable as it is easier to maintain its shape. Alternatively, the lead wire 14 may be made of a conductive wire material made of the same material as the coil 32, covered with an enamel coating for insulation. Furthermore, an uninsulated conductive wire material may be used, but in this case, an insulating distance must be ensured to ensure the insulating performance between the ground, between the coils 32, and between the lead wires 14. The cross section of the wire material may be not only circular, but also approximately rectangular.

[0024] Next, a process for wiring the crossover wires 15 of the armature 36 of the rotating electric machine of the first embodiment configured as described above will be described with reference to Figures 6 to 8. In each figure, in order to distinguish between the multiple winding assemblies 34, the winding assemblies 34 will be denoted by the reference numerals 34a, 34b, 34c, 34d, and 34e.

[0025] First, as shown in Figures 7 and 8, one end portion 15a of the crossover wire 15 is inserted into the second restraining groove 33d provided in the insulator 33a of the winding assembly 34a. Then, a bent portion 15c1 is placed above the coil 32 of the winding assembly 34a. Next, the crossover wire 15 extends toward the upper portion of the coil 32 of the circumferentially adjacent winding assembly 34b. Then, a bent portion 15c2 is placed above the coil 32 of the winding assembly 34b. Then, the crossover wire 15 extends toward the upper portion of the coil 32 of the circumferentially adjacent winding assembly 34c.

[0026] Furthermore, a bent portion 15c3 is bent above the coil 32 of winding assembly 34c. Then, the jumper wire 15 extends above the coil 32 of the circumferentially adjacent winding assembly 34d. Then, a bent portion 15c4 is bent above the coil 32 of winding assembly 34d. Then, the jumper wire 15 extends toward the second restraining groove 33d of the insulator 33a of winding assembly 34d, and the other terminal portion 15b of the jumper wire 15 is inserted into the second restraining groove 33d of the insulator 33a of winding assembly 34d.

[0027] Here, when viewed from the axial direction Y, the jumper wire 15 has four bent portions 15c1, 15c2, 15c3, and 15c4. These bent portions are the same as the number of coils 32, i.e., the number of teeth 31b, between which the jumper wire 15 is installed. Therefore, when installing the jumper wire 15, the installation positions of the bent portions 15c1, 15c2, 15c3, and 15c4 can be determined using the coils 32 of the teeth 31b as targets, thereby improving the workability of installing the jumper wire 15. Furthermore, by checking the number of bent portions 15c1, 15c2, 15c3, and 15c4, the number of teeth 31b corresponding to the coils 32 to be connected can be determined, thereby preventing mistakes in installing the jumper wire 15.

[0028] However, the number of bent portions 15c of lead wire 14 does not have to be the same as the number of teeth 31b, as long as there is a maximum of one bent portion 15c arranged above the same tooth 31b. However, as shown in Fig. 23, when connecting teeth 31b adjacent to each other in the circumferential direction Z with lead wire 14, two bent portions may be provided. In that case, as shown in Fig. 23, there will be bent portions 15c16 and 15c17, or bent portions 15c17 and 15c18, which are bent twice in different directions in the circumferential direction Z.

[0029] Next, as shown in FIG. 6 , another crossover wire 15 is placed between winding assembly 34d and winding assembly 34e. One end of this crossover wire 15 is inserted into the second constraint groove 33d of the insulator 33a of winding assembly 34d, and a bent portion 15c5 is placed above the coil 32 of winding assembly 34d. The crossover wire 15 then extends above the coil 32 of the circumferentially adjacent winding assembly 34e. A bent portion 15c6 is placed above the coil 32 of winding assembly 34e. The crossover wire 15 then extends toward the second constraint groove 33d of the insulator 33a, and the other end of the crossover wire 15 is inserted into the second constraint groove 33d of the insulator 33a of winding assembly 34e.

[0030] In this state, conductive metal pieces 60 are inserted into the restraining grooves 33c, 33d of the insulators 33a of the winding assemblies 34a, 34d, and 34e, to which the jumper wires 15 are wired. The metal pieces 60 then contact and conduct with the coil terminal 32a of the coil 32 and the terminals 15a, 15b of the jumper wire 15, thereby electrically connecting the jumper wire 15 and the coil 32. The excess terminals 15a, 15b are then cut off, resulting in the connection state shown in FIG. 6, as shown in FIGS. 7 and 8. The remaining jumper wires 15 and power supply wires 14a are then similarly connected as shown in FIG. 5, thereby completing the electrical connection between the coil 32 of the armature 36 and the lead wires 14. The field element 37, brackets 38a, 38b, and armature 36 shown in FIG. 1 are then combined, and the input portion 14b is inserted into the power supply connector 39, thereby completing the rotary electric machine 30.

[0031] Next, a method for manufacturing the lead wire 14 configured as described above will be described with reference to Figures 9 to 17. First, as shown in Figure 9, the wire 16 wound from the reel 700 by the feed shaft 70 is fed through a guide 71 and between two cylindrical protrusions 72a provided on the bending shaft 72.

[0032] Next, as shown in Fig. 10, the bending shaft 72 is rotated in a counterclockwise direction R1 to bend the wire 16 to a predetermined angle, thereby forming the bent portion 15c1. Next, as shown in Fig. 11, the bending shaft 72 is retracted toward the back of the drawing to a position where it does not come into contact with the wire 16. In this case, if a thick, rigid single wire is used, the wire will tend to return to the clockwise direction R2 due to springback when the bending shaft 72 is retracted. Therefore, if the wire is bent to a slightly larger angle in the state shown in Fig. 10 and then the bending shaft 72 is retracted, the bending accuracy can be improved.

[0033] Next, as shown in Fig. 12, the wire 16 is further fed by a preset amount by the feed shaft 70. Then, after the bending shaft 72 is rotated until the position of the protrusions 72a is in the state shown in Fig. 12, it is moved toward the front side of the paper so that the wire 16 passes between the protrusions 72a of the bending shaft 72. From this state, as shown in Fig. 13, by rotating the bending shaft 72 in a clockwise direction R2, the wire 16 is bent to a preset angle toward the upper side of the figure, forming the bent portion 15c2.

[0034] Next, as shown in Fig. 14, the bending shaft 72 is returned in a counterclockwise direction R1 to the same state as in Fig. 12, and then the wire 16 is fed by a predetermined distance using the feed shaft 70 to the state shown in Fig. 15. Then, as shown in Fig. 16, the bending shaft 72 is rotated in a clockwise direction R2 to a predetermined angle, and the wire 16 is bent to form a bent portion 15c3. Thereafter, the wire 16 is similarly fed to the desired bending position, and bending is repeated to the desired bending angle to form a bent portion 15c4. As shown in Fig. 17, the required shape of the lead wire 14 is formed, and the lead wire 14, in this case one of the crossover wires 15 shown in Fig. 7, is formed by cutting it to the required length.

[0035] Thus, according to the armature 36 of the rotating electric machine 30 of embodiment 1, even if a thick single wire with high rigidity is used for the lead wire 14 in order to bend and shape it, by taking rigidity into consideration and setting the bending angle slightly larger, it is possible to shape the lead wire 14 into a predetermined shape by springback, thereby improving the shape accuracy of the lead wire 14 after forming.

[0036] 9 to 17, multiple bent portions 15c1, 15c2, 15c3, and 15c4 can be automatically formed in order, improving the workability of manufacturing lead wire 14. Furthermore, according to the manufacturing methods shown in Figures 9 to 17, even when forming multiple types of jumper wires 15 with different shapes, lead wires 14 formed to a predetermined shape can be manufactured using a single device simply by setting the feed amount and bending angle, which reduces the number of types of jigs and the effort required for changeover, improving the workability of forming lead wire 14.

[0037] Furthermore, an example has been shown in which the coil terminal portion 32a of the coil 32 constituting the winding assembly 34 is inserted into the first constraining groove 33c, and the terminal portions 15a, 15b of the lead wire 14 are inserted into the second constraining groove 33d from the inside X2 to the outside X1 in the radial direction X of the outer flange portion 33a1, but this is not limitative. For example, the coil terminal portion 32a of the winding assembly 34a in FIG. 6 may be inserted into the first constraining groove 33c, and the coil terminal portion 32a of the winding assembly 34d may be inserted into the second constraining groove 33d, or the coils may be inserted into the respective constraining grooves 33c, 33d at positions that make insertion easier.

[0038] In addition, an example has been described in which the coil terminal portion 32a and the terminal portions 15a, 15b of the lead wire 14 are electrically connected by inserting them into the respective restraining grooves 33c, 33d of the insulator 33a and placing the metal piece 60 therein to establish electrical contact and conduction. However, this is not limited to this example. For example, the coil terminal portion 32a and the terminal portions 15a, 15b of the lead wire 14 may be electrically connected by brazing, soldering, crimp terminals, or insulation displacement terminals. Furthermore, the lead wire 14 is not fixed at any portion other than the connection end. Note that the lead wire 14 may be fixed at any portion other than the connection end by a molded portion 41, as shown in FIG. 24 .

[0039] Note that the bent portions shown above are not formed on the outer side X1 of each insulator in the radial direction X. Also, there are multiple bent portions for one lead wire shown above in the circumferential direction Z. Also, the multiple bent portions for one lead wire shown above are not formed in overlapping positions in the axial direction Y.

[0040] According to the armature of the rotating electric machine of embodiment 1 configured as described above, the armature of the rotating electric machine includes an armature core having a yoke portion formed in an annular shape and a plurality of teeth portion that protrude radially inward from the inner periphery of the yoke portion and are formed at intervals in the circumferential direction, insulating members installed on each of the teeth portion, coils wound around the teeth portion via the insulating members, and lead wires electrically connected to at least one of the winding start terminal portion or the winding end terminal portion of the coil, wherein the lead wires have a plurality of bent portions when viewed from the axial direction, and therefore can be installed simply by forming bent portions in the lead wires, which makes wiring of the lead wires easier, shortens work time, and reduces investment costs.

[0041] Furthermore, according to the rotating electric machine of embodiment 1 configured as described above, since it is equipped with the rotating electric machine armature described above, it can be installed simply by forming a bent portion in the lead wire, which makes wiring work of the lead wire easier, shortens work time, and reduces investment costs.

[0042] Furthermore, according to the manufacturing method for the lead wire of the armature of the rotating electric machine of embodiment 1 performed as described above, after repeating a feeding process in which a reel-shaped wire is fed out by a predetermined length and a bending process in which the wire is bent at a predetermined angle, the wire is cut at a predetermined position to form the lead wire having a plurality of the bent portions. Therefore, since the lead wire can be installed simply by forming the bent portions, the wiring work for the lead wire can be facilitated, the working time can be shortened, and the investment cost can be reduced.

[0043] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the number of the bent portions of the lead wire, when viewed from the axial direction, is the same as the number of the teeth portions that exist between the electrically connected portions and at least one of the winding start terminal portion or the winding end terminal portion of the coil.Therefore, by checking the number of bent portions, the number of teeth portions that exist between the connected portions can be determined, thereby preventing mistakes in installing the lead wire.

[0044] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the bent portion of the lead wire is positioned above the area where the coil is wound when viewed from the axial direction, which makes it easier to wire the lead wire, shortens the work time, and reduces investment costs.

[0045] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the bent portions of the lead wires are arranged in an axial direction without being formed in overlapping positions, which further simplifies the wiring work of the lead wires, shortens the work time, and reduces investment costs.

[0046] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the lead wire is connected at the connection end to a terminal that contacts at least one of the winding start terminal portion or the winding end terminal portion of the coil, which makes the wiring work of the lead wire easier, shortens the work time, and reduces investment costs.

[0047] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the lead wires are not fixed at any part other than the connection end, which makes it easier to wire the lead wires, shortens the work time, and reduces investment costs.

[0048] Furthermore, according to the armature of the rotating electric machine of embodiment 1 configured as described above, the lead wires are fixed by the molded portion at the portions other than the connection ends, which makes it easier to wire the lead wires, shortens the work time, and reduces investment costs.

[0049] Embodiment 2. Fig. 18 is a plan view showing the configuration of an armature for a rotating electric machine according to embodiment 2. Figs. 19 to 21 are plan views illustrating the process of wiring lead wires to the armature for the rotating electric machine shown in Fig. 18. Fig. 22 is a plan view illustrating the process of wiring other lead wires to the armature for the rotating electric machine according to embodiment 2. In the figures, parts that are the same as those in embodiment 1 above will be omitted and will be assigned the same reference numerals. Furthermore, parts that are the same as those in embodiment 1 above will be described using the same reference numerals. Furthermore, this also applies to the following embodiments, and therefore description thereof will be omitted as appropriate.

[0050] In the first embodiment described above, as shown in Fig. 7, an example was shown in which the jumper wire 15 is bent above the coils 32 of each of the winding assemblies 34a to 34d through which the jumper wire 15 passes, forming bent portions 15c1, 15c2, 15c3, and 15c4, but the present invention is not limited to this. Also, as shown in Fig. 6, an example was shown in which the jumper wire 15 passes near the center of the coils 32 of the winding assembly 34 in the radial direction X, but the present invention is not limited to this. In the second embodiment, other examples of the jumper wire 15 will be described. Note that descriptions of other parts similar to those in the first embodiment will be omitted as appropriate.

[0051] As shown in Figure 19, one end portion 15a of the crossover wire 151 is inserted into the second restraining groove 33d provided in the insulator 33a of the winding assembly 34a. Then, a bent portion 15c7 is bent near the outer flange portion 33a1 of the insulator 33a of the winding assembly 34a. Next, the crossover wire 15 extends to between the circumferentially adjacent winding assemblies 34b and 34c in the circumferential direction Z. Then, a bent portion 15c8 is bent at the top between the circumferentially adjacent winding assemblies 34b and 34c in the circumferential direction Z. Then, the crossover wire 15 extends to near the outer flange portion 33a1 of the insulator 33a of the winding assembly 34d, which is adjacent in the circumferential direction Z, and a bent portion 15c9 is bent near the outer flange portion 33a1 of the insulator 33a. Then, the crossover wire 15 extends toward the second restraining groove 33d of the insulator 33a of the winding assembly 34d, and the other end portion 15b of the crossover wire 15 is inserted into the second restraining groove 33d of the insulator 33a of the winding assembly 34d.

[0052] Thus, in the present embodiment 2, unlike the above-described embodiment 1, the upper part of the coil 32 of the winding assembly 34b and the upper part of the coil 32 of the winding assembly 34c do not have a bent portion. Therefore, with the jumper wire 151 of the present embodiment 2, the number of bends can be reduced by one compared to the above-described embodiment 1, and the time required for the formation operation of the jumper wire 151 can be shortened.

[0053] 19, the crossover wire 151 is arranged along a path that makes contact with the inner flange portions 33a2 of the insulators 33a of the winding assemblies 34b and 34c. With this configuration, the position of the crossover wire 151 is stabilized after wiring, and the crossover wire 151 is less likely to shift when another lead wire is arranged, improving the ease of wiring work.

[0054] Next, as shown in Figure 20, another crossover wire 152 is arranged between winding assembly 34d and winding assembly 34e. One end portion 15a of this crossover wire 152 is inserted into the second restraining groove 33d of the insulator 33a of winding assembly 34d, and a bent portion 15c10 is provided by bending the crossover wire 152 near the insulator 33a of winding assembly 34d. The crossover wire 15 then extends so as to contact the inner flange portion 33a2 of the insulator 33a of the winding assembly 34e that is adjacent in the circumferential direction Z. A bent portion 15c11 is then provided by bending the crossover wire 152 near the inner flange portion 33a2 of the insulator 33a of winding assembly 34e. Then, the crossover wire 15 extends toward the second restraining groove 33d of the insulator 33a, and the other end portion of the crossover wire 15 is inserted into the second restraining groove 33d of the insulator 33a of the winding assembly 34e.

[0055] Furthermore, as shown in FIG. 20, the crossover wire 152 is arranged along a path that brings it into contact with the inner flange portion 33a2 of the insulator 33a, so that the position of the crossover wire 152 is stable, and the same effect as in the above case is achieved.

[0056] 21 , the power supply wires 141 are bent a number of times less than when the power supply wires 141, 142 are bent above the coils 32 of each winding assembly 34, but the bent portions are four, 14c1, 14c2, 14c3, and 14c4, when viewed from the axial direction Y. The power supply wire 142 is bent a number of times less than when the power supply wires 141, 142 are bent above the coils 32 of each winding assembly 34, but the bent portions are two, 14c5 and 14c6, when viewed from the axial direction Y. The shapes of the power supply wires 141, 142 are formed in this manner, which reduces the forming work time.

[0057] Furthermore, the power lines 141 and 142 are routed through a path that contacts not only the inner flange 33a2 of the insulator 33a but also the outer flange 33a1 of the insulator 33a, which further stabilizes the positions of the power lines 141 and 142.

[0058] In this way, the number of bending points of the lead wire 14 when viewed from the axial direction Y is fewer than the number of teeth 31b (coils 32) present between the connection ends of the lead wire, thereby shortening the time required for forming the lead wire 14. Furthermore, because the lead wire 14 has a portion other than the connection end that is disposed in contact with the insulator 33, the position of the lead wire 14 after wiring is stable and is less likely to shift when another lead wire 14 is disposed, improving wiring workability. Furthermore, the lead wire 14 does not shift during material handling and subsequent processes after wiring, eliminating the need for rework, and an inexpensive armature for a rotating electric machine can be provided.

[0059] The shape of lead wire 14 is not limited to this. For example, as shown in FIG. 22, bends 15c12, 15c13, 15c14, and 15c15 may be formed, and jumper wire 151 may be routed through a path that contacts not only inner flange 33a2 of insulator 33a but also outer flange 33a1 of insulator 33a. This configuration further stabilizes the position of jumper wire 151.

[0060] The armature of the rotating electric machine of embodiment 2 configured as described above has the same effect as embodiment 1 described above, and the number of bent portions of the lead wire, when viewed from the axial direction, is less than the number of teeth portions that exist between the electrically connected portions and at least one of the winding start terminal portion or the winding end terminal portion of the coil, so that the number of bends can be reduced to shorten the working time for shaping the lead wire.

[0061] Furthermore, according to the armature for a rotating electric machine of the second embodiment configured as described above, the lead wires have portions other than the connection ends that are in contact with the insulating member, and since the lead wires are in contact with the insulating member, the position of the lead wires can be stabilized, shortening the wiring work time. Furthermore, even after wiring, the lead wires do not shift during material handling and subsequent processes, eliminating the need for rework, and making it possible to provide an inexpensive armature for a rotating electric machine.

[0062] Embodiment 3. Fig. 25A is a cross-sectional view showing wire material forming a coil of a rotating electric machine according to embodiment 3. Figs. 25B and 25C are cross-sectional views showing wire material forming a lead wire and a crossover wire of a rotating electric machine according to embodiment 3. The wire material forming the coil 32 of a rotating electric machine having the structure described in each of the above embodiments, and the wire material forming the lead wire 14 and the crossover wire 15 will be described.

[0063] First, as shown in FIG. 25A , the wire forming the coil 32 is formed of a coil conductor 32c2 and an enamel coating 32c1 that covers the outer periphery of the coil conductor 32c2 to a thickness W1. In contrast, as shown in FIGS. 25B and 25C , the wire forming the lead wire 14 and the crossover wire 15 is formed of a solid wire 15d2 or a stranded wire 15d3 and an outer coating 15d1 that covers the outer periphery of the solid wire 15d2 or the stranded wire 15d3 to a thickness W2 or W3. This structure allows electrical connection using wires with an insulating structure. The outer coating 15d1 is formed of, for example, a fluorine-based resin or PVC (polyvinyl chloride), and is stronger and more elastic than the enamel coating 32c1.

[0064] Furthermore, because the thicknesses W2 and W3 of the outer coating 15d1 are greater than the thickness W1 of the enamel coating 32c1 covering the outer periphery of the coil conductor 32c2, the outer coating 15d1 is less likely to tear than the enamel coating 32c1 of the coil 32 when forming the bent portion, ensuring insulation strength. Furthermore, the stranded wire 15d3 is more easily deformed than the solid wire 15d2, which has the advantage of requiring less force for forming. Note that the thickness W3 of the outer coating 15d1 for the stranded wire 15d3 indicates the minimum distance from the outermost diameter of the stranded wire 15d3 to the outer diameter of the outer coating 15d1.

[0065] The armature for a rotating electric machine according to the third embodiment configured as described above has the same effects as those of the above embodiments, and in addition, since the thickness of the outer coating of the lead wire is thicker than the thickness of the outer coating of the coil, an insulating distance and insulating strength can be ensured. Furthermore, since the armature has excellent strength and elasticity, it is less likely to break and insulating strength can be further ensured.

[0066] Furthermore, according to the armature of the rotating electric machine of the third embodiment configured as described above, the conductor that is the core wire of the lead wire is formed of a stranded wire, which is easier to deform than a solid wire and is therefore excellent for forming operations.

[0067] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are contemplated within the scope of the disclosed technology. For example, this includes cases where at least one component is modified, added, or omitted, and even cases where at least one component is extracted and combined with components of another embodiment.

[0068] Various aspects of the present disclosure are summarized below as appendices.

[0069] (Supplementary Note 1) An armature for a rotating electric machine comprising: an armature core having a yoke portion formed in an annular shape, and a plurality of teeth portion projecting radially inward from the inner periphery of the yoke portion and formed at intervals in the circumferential direction, insulating members installed on each of the teeth portion, coils wound around the teeth portion via the insulating members, and lead wires electrically connected to at least one of a winding start end portion and a winding end end portion of the coil, wherein the lead wires have a plurality of bent portions when viewed in the axial direction. (Supplementary Note 2) The armature for a rotating electric machine according to Supplementary Note 1, wherein the number of bent portions of the lead wires is the same as the number of the teeth portion present between the electrically connected portions and at least one of a winding start end portion and a winding end end portion of the coil when viewed in the axial direction. (Supplementary Note 3) The armature of a rotating electric machine according to Supplementary Note 1, wherein the number of bent portions of the lead wire, when viewed in the axial direction, is smaller than the number of the teeth present between the lead wire and at least one of a winding start terminal portion or a winding end terminal portion of the coil and which are electrically connected to the lead wire. (Supplementary Note 4) The armature of a rotating electric machine according to any one of Supplementary Note 1 to Supplementary Note 3, wherein the lead wire has a portion other than the connection end portion that is arranged in contact with the insulating member. (Supplementary Note 5) A rotating electric machine including the armature of a rotating electric machine according to any one of Supplementary Note 1 to Supplementary Note 4. (Supplementary Note 6) A method of manufacturing a lead wire for an armature of a rotating electric machine according to any one of Supplementary Note 1 to Supplementary Note 4, comprising repeating a feeding step of feeding out a reel-shaped wire by a predetermined length and a bending step of bending the wire at a predetermined angle, and then cutting the wire at a predetermined position to form the lead wire having a plurality of the bent portions.

[0070] 14 Lead wire, 14a Power supply wire, 14b Input section, 14c1 Bent section, 14c2 Bent section, 14c3 Bent section, 14c4 Bent section, 14c5 Bent section, 14c6 Bent section, 15 Jumper wire, 15c Bent section, 15c1 Bent section, 15c2 Bent section, 15c3 Bent section, 15c4 Bent section, 15c5 Bent section, 15c6 Bent section, 15c7 Bent section, 15c8 Bent section, 15c9 Bent section, 15c10 Bent section, 15c11 Bent section, 15c16 Bent section, 15c17 Bent section, 15c18 Bent section, 15d1 Outer coating, 15d2 Solid wire, 15d3 Stranded wire, 30 Rotating electric machine, 35 frame, 36 armature, 37 field element, 31 laminated core, 310 electromagnetic steel sheet, 31a yoke portion, 31b teeth portion, 31c protrusion portion, 32 coil, 32a coil end portion, 32c1 enamel coating, 32c2 coil conductor, 33 insulator, 33a insulator, 33b insulator, 33c first restraining groove, 33d second restraining groove, 33a1 outer flange portion, 33b1 outer flange portion, 33a2 inner flange portion, 33b2 inner flange portion, 33a3 body portion, 33b3 body portion, 34 winding assembly, 38a bracket, 38b bracket, 39 power connector, 41 molded portion, R1 counterclockwise direction, R2 clockwise direction, X radial direction, X1 outer side, X2 Inside, Y axis direction, Z circumferential direction.

Claims

1. An armature core having an annular yoke portion and a plurality of teeth portions that project radially inward from the inner peripheral side of the yoke portion and are formed at intervals in the circumferential direction, An insulating member installed on each of the teeth portions, A coil wound around the teeth portion via the insulating member, An armature of a rotating electrical machine including a lead wire electrically connected to at least one of the start winding terminal portion or the end winding terminal portion of the coil, The lead wire has a plurality of bent portions when viewed in the axial direction, Both ends of the lead wire project radially outward with respect to the bent portions closest to both ends of the lead wire, respectively. An armature of a rotating electrical machine.

2. The armature of the rotating electrical machine according to Claim 1, wherein the lead wire is formed on the same plane.

3. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the thickness of the outer coating of the lead wire is thicker than the thickness of the outer coating of the coil.

4. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the conductor, which is the core wire of the lead wire, is formed of a stranded wire.

5. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the number of the bent portions of the lead wire is the same as the number of the teeth portions existing while being electrically connected to at least one of the start winding terminal portion or the end winding terminal portion of the coil when viewed in the axial direction.

6. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the number of the bent portions of the lead wire is less than the number of the teeth portions existing while being electrically connected to at least one of the start winding terminal portion or the end winding terminal portion of the coil when viewed in the axial direction.

7. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the bent portions of the lead wire are arranged on the region where the coil is wound when viewed in the axial direction.

8. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the bent portions of the lead wire are arranged without being formed at overlapping positions in the axial direction.

9. The armature of the rotating electrical machine according to Claim 1 or Claim 2, wherein the lead wire has a portion in contact with the insulating member at a portion other than the connection end portion.

10. The armature of the rotating electrical machine according to claim 9, wherein the lead wire is in contact with at least one of an outer flange portion provided radially outside the body portion around which the coil is wound in the insulating member or an inner flange portion provided radially inside the body portion.

11.

11. The armature of the rotating electrical machine according to claim 1 or claim 2, wherein the lead wire is connected to a terminal that is in contact with at least one of the start terminal portion or the end terminal portion of the coil at the connection end portion.

12. The armature of the rotating electrical machine according to claim 11, wherein the terminal is a conductive terminal fixed to an outer flange portion provided radially outside the body portion around which the coil is wound in the insulating member.

13. An armature core having an annular yoke portion and a plurality of tooth portions that project radially inward from the inner peripheral side of the yoke portion and are formed at intervals in the circumferential direction, an insulating member provided on each of the tooth portions, a coil wound around the tooth portion via the insulating member, and a lead wire electrically connected to at least one of the start terminal portion or the end terminal portion of the coil, wherein the lead wire has a plurality of bent portions when viewed in the axial direction, and the portion other than the connection end portion is not fixed.

14.

14. The armature of the rotating electrical machine according to claim 1 or claim 2, wherein the portion other than the connection end portion of the lead wire is fixed by a molding portion.

15.

15. A rotating electrical machine including the armature of the rotating electrical machine according to claim 1 or claim 2.

16.

16. A method for manufacturing a lead wire of an armature of a rotating electrical machine according to claim 1 or claim 2, comprising repeating a feeding step of feeding out a length of a reel-shaped wire material provided in advance and a bending step of bending the wire material at a preset angle, and then cutting the wire material at a preset position to form the lead wire having a plurality of the bent portions. ​ ​